Takeuchi Mini Excavator TB216 (No.216000002~, No.216100002~). Operator's Manual

Operation

Handling rubber crawlers

Cautions

Observe the following cautions when

operating the machine:

• Rubber crawler belts are not as stable as

steel crawler belts since the entire lugs are

made of rubber. Be very careful when

slewing and swinging sideways.

• Do not turn the undercarriage with the front

of the machine body lifted using the hoe

Preventing the rubber crawlers

attachment (the upperstructure is not

from coming off

turned). Doing so will twist the crawlers

with the load concentrated on a single

Observe the following cautions to prevent

point on the crawler belt, causing rapid

the crawler from coming off.

damage to the crawlers.

• Always keep the crawlers at the proper

• Avoid changing course abruptly or spin-

tension.

turning on concrete surfaces whenever

possible. Doing so may wear or damage

the rubber crawlers.

• Avoid drops that may expose the rubber

crawlers to strong shocks.

• Salt, potassium chloride, ammonium

sulfate, potassium sulfate, and triple

superphosphate of lime can damage the

crawler belts. If any of these substances

gets on the crawler belts, wash if off

thoroughly with water.

• Do not let the sides of the rubber crawlers

rub against concrete or walls.

• When traveling over a large step such as a

• Do not damage the rubber crawlers by

cobblestone or rock (20 cm (8 in.) or

hitting the bucket against them.

deeper), climb up the step at the right

• Be especially careful on snowy or frozen

angle and do not change courses on top of

surfaces in winter, as the crawler belts tend

the step.

to slip in such conditions.

• Use rubber crawler belts at temperatures

between -25°C to +55°C (-14°F to 131°F).

• When storing the rubber crawlers for long

periods of time (three months or more), do

so indoors in a place not exposed to direct

sunlight or rain.

3-29

Operation

Handling rubber crawlers

• When climbing in reverse, do not change

• Do not change directions when the crawler

directions at the point where the slope

belts are slack as shown in the figure.

starts.

• The rubber crawler belts will come off if the

• Avoid traveling by setting one crawler on a

machine travels backward in this condition.

slope or projecting portion and the other

crawler on a flat surface (with the machine

at a tilt of 10° or more). Travel with both

crawlers set on flat surfaces.

• The rubber crawler belts will come off if the

machine turns in this condition.

3-30

Transport

Loading and unloading

When loading or unloading the machine, be

Loading and unloading

sure to use ramps or a platform and follow

the procedure below.

The machine may roll or tip over or fall

while being loaded or unloaded. Take the

following precautions:

• Select a firm, level surface and keep

sufficient distance from road shoulders.

• Secure the ramps of adequate strength

and size to the truck bed. The slope of

the ramps must not exceed 15°. If the

rumps are bowed down too low,

support them with poles or blocks.

• Never use the working equipment to

load or unload the machine. Doing so

1. Set the parking brake on the transporter

may result in tipping over or falling

and chock the wheels.

down of the machine.

2. Fix the ramps securely to the truck bed.

• Keep the truck bed and loading ramps

The slope of the ramps must not exceed

clean of oil, soil, ice, snow, and other

15°.

materials to prevent the machine from

3. Align the center of the truck bed with the

sliding sideways. Clean the crawlers.

center of the machine, and of the ramp

• Chock the transporter wheels to prevent

with the center of the crawler.

movement.

4. Make sure the dozer blade does not hit

• When being loaded or unloaded, travel

the ramps.

slowly in 1st (low) gear by following the

5. Lower the hoe attachment as far as

signal from the signal person.

possible without letting it touch the

• Never change courses on the ramp.

transporter.

• Do not slew/swing on the ramp. The

6. Decrease the engine speed.

machine may tip over.

• When slewing/swinging on the truck

bed, do it slowly as the footing should

be unstable.

• Lock the cab door after being loaded, if

applicable. Otherwise, the door may

open during transport.

• Chock the tracks and secure the

machine to the truck bed with wire rope

or chain.

4-2

Transport

Hoisting the machine

Hoisting

Hoisting the machine

1. Slew the upperstructure so that the dozer

blade is at the rear of the machine (set the

upperstructure parallel to the track frame).

• Know and use the correct crane signals.

2. Raise the dozer blade fully.

• Check the hoisting equipment for

3. Extend the bucket cylinder and arm

damaged or missing parts on a daily

cylinder fully to raise the boom to its

basis and replace as necessary.

uppermost position.

• When hoisting, use a wire rope capable

4. If the boom is swung to either the left or

of lifting the machine mass.

right side, set it in the neutral position.

• Hoist the machine in such a manner

5. Raise the safety lock lever to the locked

described in the procedure below. Do

position.

not do it in any other manner. Doing so

6. Stop the engine, remove the starter key

is dangerous as it may result in the

and get off the machine.

machine losing its balance.

7. Install the wire ropes as shown on the

• Do not hoist the machine with an

figure below. Install the wire ropes and

operator on it.

hoisting attachment without letting them

• When hoisting, hoist slowly so that the

touch the machine body.

machine does not tip.

8. Hoist the machine slowly until it leaves the

• Keep everyone out of the area when

ground.

hoisting. Do not move the machine over

9. Stop hoisting until the machine becomes

the heads of the persons.

stable, and then start hoisting the machine

slowly again.

IMPORTANT: This hoisting method

applies to machines with standard

specifications. The center of gravity

differs according to the attachments and

optional equipment installed.

Contact your Takeuchi service agent for

details.

4-4

Transport

Securing the machine

After loading the machine at the specified position, secure it as described below.

Transporting posture

1. Lower the dozer blade.

Precautions to be taken during

2. Extend the bucket cylinder and arm

transportation

cylinder fully, and then lower the boom.

3. Raise the safety lock lever to the locked

position.

• Know and follow the applicable safety

4. Stop the engine, remove the starter key

rules, vehicle code and traffic laws

and lock all locks.

when transporting the machine.

5. Place the stoppers (chocks) in front and

• Select the best transport route by

behind the crawlers.

considering the length, width, height

6. Install a chain or wire rope over the lower

and weight of the truck with the

frame of the machine and fasten it

machine loaded on it.

securely to prevent the machine from

• Never abruptly start or stop or run at a

slipping sideways.

high speed at the sharp curves during

7. Secure the bucket with a chain or wire

transport. Doing so will move or lose the

rope.

balance of the loaded machine.

IMPORTANT: Place a wooden block under

the bucket to protect the floor from

damage caused by the bucket.

4-6

Maintenance

General

Cautions on maintenance

General

Maintenance overview

Do not perform any other inspection and

maintenance works than those listed in this

To keep the machine in good condition and

manual.

use if for a long period, perform the

For works not listed in this manual, ask your

inspection and maintenance properly and

sales or a service dealer for help.

safely following the procedures

recommended by this manual.

Keep the machine clean

• Clean the machine before performing

The inspection and maintenance items are

inspection and maintenance and try to

divided into groups according to the

keep it clean.

machine’s total operating time: every 10

• Stop the engine before washing the

hours (walk-around and daily inspection),

machine. Cover the electrical parts so that

every 50 hours, every 250 hours, etc. Refer

water cannot enter. Water on electrical

to the hour meter readings to determine

parts could cause short-circuits or

when to schedule an inspection and

malfunctions. Do not use water or steam to

maintenance. Items for which it is not

wash the battery, electronic control

possible to determine the inspection and

components, sensors, connectors or the

maintenance interval are included under

operator’s compartment.

“When Required”.

Fuel, lubricant and grease

When operating the machine in extremely

• Choose fuel, lubricant and grease by

harsh environments (with high dust levels or

following to the “Fuel and lubricant table”.

high temperatures), inspection and

• Use fuels, lubricants and greases which do

maintenance should be performed earlier

not contain water, and be careful to keep

than the times specified on the Maintenance

dirt out when changing or replenishing fuel,

List.

lubricant or grease.

• Store fuels, lubricants and greases in the

prescribed places and in such a way that

no water or dirt can get in them.

Cautions on refueling

• If the port includes a strainer, do not

remove the strainer when fueling.

• After fueling, be sure to securely tighten the

fuel filler cap.

• Do not add more than the specified

amount of fuel.

Do not use fuel to clean parts

Do not use fuel to clean parts. Use a non-

combustible cleaning agent.

Keep dirt out

When mounting and removing parts, do so in

a place where there is no dust, clean the

working area and the part, and keep dirt out.

5-2

Maintenance

General

Clean the installation surfaces

Cautions on handling of battery wiring

When installing and removing parts, be sure

• Disconnect the wiring from the both

that the surfaces of contact of the parts are

terminals (+ and -) on the battery before

clean. If the sealing grooves of the surface of

working on the electrical system or doing

contact are damaged, consult your sales or

electric welding.

service dealer for repair or release.

Always disconnect it from the earth side

(-). When connecting, connect the earth

Seals and split pins

side last.

• Be sure to replace all seals and cotter pins

• Do not disconnect the battery wiring while

with new ones.

the engine is moving. Otherwise, the

• When installing, be careful not to damage

electric circuits of the rotary converter or

or twist the seal.

others may be damaged.

Sealing tape

• When wrapping the plug with sealing tape,

remove any old sealing tape from the

threads and clean the threads.

• Wrap the thread tight with seal tape

starting 1 or 2 threads away from the

thread end.

Disposing of wastes

• Always collect oil that is drained from the

machine in containers. Improperly

disposed waste oil can cause

environmental harm.

• Follow appropriate laws and regulations

when disposing of harmful objects such as

oil, fuel, cooling water, coolant, filters and

batteries.

Check after maintenance

• Gradually increase the engine speed from a

low idle to maximum speed and check that

there is no oil or water leaking from

serviced parts.

• Operate each control lever and check that

the machine is operating properly.

5-3

Maintenance

Service data

Fuel and lubricant table

Select the appropriate fuel, lubricant and grease according to the temperature by referring to

the table below.

• Regardless of the specified time, change the oil if it becomes too dirty or degraded.

• When refilling, never mix oils of different brands. If a brand is to be changed, replace the

whole fuel/oil.

Fuel

Diesel fuel specifications

Diesel fuel should comply with the following specifications. The table lists several worldwide

specifications for diesel fuels.

Diesel fuel specification

Location

Diesel fuel specification

Location

ASTM D975

No.1-D, S15

No.2-D, S15

USA

ISO 8217DMX

International

Bio-diesel fuel

Canada

Biodiesel blends up to B5

ASTM D6751, D7467

EN590: 96

Bio-diesel fuel

European union BS2869-A1 or A2

United kingdom

Biodiesel blends up to B5

EN14214, EN590

5-4

Maintenance

Service data

To maintain the performance and service life of the engine,

always use clean and high-quality fuel.

• To avoid freezing in cold climates, use a diesel fuel that still

functions when the temperature is at least 12°C (53.6°F) below

the lowest expected ambient temperature.

• Use a diesel fuel that has a cetane number of 45 or higher.

When operating at a very low temperature or at a high altitude,

a higher cetane number fuel will be required.

• Use fuel with sulfur content of less than 0.05 to 0.0015% by

volume.

Especially in the U.S.A. and Canada, ultra-low sulfur fuel

should be used.

A higher sulfur content fuel may cause sulfuric acid corrosion

Fuel tank

Diesel fuel

in the cylinders of the engines.

• Never mix kerosene, used engine oil, or residual fuel with the

diesel fuel. Use of kerosene is prohibited.

• Poor quality fuel can reduce engine performance and / or

cause engine damage.

• Fuel additives are not recommended. Some fuel additives may

cause poor engine performance.

• The content of metal, such as zinc, sodium, magnesium,

silicon and aluminum, must be 1 mass ppm or less. (JPI-

5S-44-95 test analysis method)

Precautions when using bio-diesel fuel

The warranty of the engine manufacturer may be voided by

using a bio-diesel fuel that does not meet the standard or that is

deteriorated.

5-5

Maintenance

Service data

Lubricant

Type by air temperature

Location

Type

-4

86 104°F

When to replace

-20 -10

30 40°C

Diesel engine oil

Every 250 hrs.

SAE 10W-30

Engine oil pan

API: CD class

after the initial

SAE 15W-40

ACEA: E-3, E-4 or E-5

50 hrs.

Takeuchi genuine

Every 4000

ISO VG46

hydraulic oil 46

hrs.***

Hydraulic oil

ISO VG32

tank

Every 2000

Anti-wear hydraulic oil

ISO VG46

hrs.***

ISOVG68

Cooling water (water +

Engine cooling

Mixture of 50% coolant

coolant)**

Every 1000 hrs.

system

Mixture of 30% coolant

SAE: J814C or J1034

Every 1000 hrs

Travel reduction

Gear oil

SAE 90

after the initial

gear

API: GL-4

250 hrs*.

Slew motor

Every 50 hrs.

pinion

Lithium based grease

Slew bearing

Every 50 hrs.

EP-2

—

Working

Daily or every

NLGI No.2

equipment

10 hrs.

Levers

When required

* : If the ratio of traveling time to total operating time is high, replace the gear oil earlier than

the specified time.

** : For water, use tap water (soft). Do not use well or river water. When the ambient

temperature drops below 0°C (32°F), add coolant (antifreeze). Follow the coolant

manufacturer’s instructions to determine the mixture ratio.

*** :The hydraulic oil replacement interval depends on the type of hydraulic oil being used. New

machine are delivered with Takeuchi genuine hydraulic oil 46, and the hydraulic oil

replacement intervals indicated in this manual assume that Takeuchi genuine hydraulic oil

46 is being used. When using conventional antiwear hydraulic oil, the hydraulic oil should

be replaced every 2000 hours.

5-6

Maintenance

Service data

Regularly replace the hydraulic

oil

When a hydraulic breaker is used, the oil

deteriorates more quickly than that used for

a usual excavation operation. Be sure to

replace the hydraulic oil and the return filter

elements.

• Failure to replace these in time can lead to

damage to the machine and the breaker

hydraulic system. To prolong the service life

of the hydraulic devices, properly replace

the hydraulic oil and the return filter

elements according to the table below.

• When replacing the hydraulic oil, clean the

suction strainer.

Replacement interval (hours)

( ):

When a conventional antiwear hydraulic

oil is used.

Item

Hydraulic oil

Filter element

1st time

—

2nd time

—

100

Periodically

1200 (600)

200

When the breaker operating ratio is 100%.

Refer to “Hydraulic breaker” on page 8-6.

5-8

Maintenance

Service data

List of consumables

Periodically replace consumables such as filters and elements according to the table below.

System

Item

Part name

Part No.

When to replace

Hydraulic oil

Every 500 hrs after

Hydraulic system

Element

15511-01300

return filter

the initial 50 hrs.

Engine lubrication

Every 250 hrs after

Engine oil filter

Cartridge

Y119305-35160

system

the initial 50 hrs.

Water separator

Y171081-55910

filter

Fuel system

Element

Every 500 hrs.

Fuel filter

Y119810-55650

Every 1000 hrs. or

Primary (Outer)

after 6 cleanings

Y119515-12520

element

(whichever comes

first)

Air cleaner system

Air cleaner

When the primary

Secondary

19111-01342

elements are

(Inner) element

replaced.

5-9

Maintenance

Service data

List of tools

Code

Part name

Part No.

Remarks

Spanner

19100-47081

10 - 12

Spanner

19100-47082

14 - 17

Screwdriver

19100-06112

(+) (-) replaceable shank

Filter wrench

19100-96081

Monkey wrench

16904-00250

250 mm

Pliers

16905-00200

200 mm

Spanner

16901-00013

Spanner

16900-01922

19 - 22

Spanner

16909-00026

Tool case

16914-00005

Grease gun

16910-60600

600 cc

Drain connector

15545-12201

5-10

Maintenance

Service data

List of tightening torques

Nuts and Bolts (for ISO strength category 10.9)

Tighten nuts and bolts at the torques shown on the table below, unless otherwise specified.

• The tightening torques used for the mounted plastic covers are not listed in the table below.

Consult your sales or service dealer for details. They will be damaged if over tightened.

• When replacing nuts and bolts, replace them with nuts and bolts of the same size and

standards.

• Tighten nuts and bolts alternately (top, bottom, left then right) or in 2 or 3 times so that they

are evenly tightened.

Tightening torque

Head width (b)

Size (a) x pitch

Classification

General connection points

N·m

ft-lb.

M6 x 1.0

9.8±0.5

7.2±0.4

12, 13

M8 x 1.25

22.6±1.1

16.6±0.8

14, 17

M10 x 1.5

47.1±2.4

34.7±1.7

Coarse

17, 19

M12 x 1.75

83.4±4.1

61.5±3.0

19, 22

M14 x 2.0

134.4±6.7

99.1±4.9

22, 24

M16 x 2.0

207.9±10.4

153.3±7.7

27, 30

M20 x 2.5

410.9±20.5

303.1±15.1

12, 13

M8 x 1.0

24.5±1.2

18.1±0.9

14, 17

M10 x 1.25

50±2.5

36.9±1.8

17, 19

M12 x 1.5

87.3±4.3

64.4±3.2

Fine

19, 22

M14 x 1.5

135.3±6.8

99.8±5.0

22, 24

M16 x 1.5

220.6±11

162.7±8.1

27, 30

M20 x 1.5

452.1±22.6

333.4±16.6

5-11

Maintenance

Safety-critical parts

To use the machine safely, periodically perform inspection and maintenance. The safety-critical

parts listed below must be periodically replaced for an increased safety.

Serious injury or a fire could result if they are worn or damaged.

List of safety-critical parts

Unit

Safety-critical parts to be replaced periodically

When to replace

Fuel hoses

Fuel system

Packing on fuel filler cap

Hydraulic hoses (pump - delivery)

Hydraulic hoses (pump - suction)

Main body

Hydraulic hoses (slew motor)

Hydraulic hoses (travel motor)

Hydraulic hoses (boom cylinder piping)

Every 2 years

Hydraulic hoses (arm cylinder piping)

Hydraulic

system

Hydraulic hoses (bucket cylinder piping)

Hydraulic hoses (swing cylinder)

Working

equipment

Hydraulic hoses (blade cylinder)

Hydraulic hoses (span cylinder)

Hydraulic hoses (pilot valve)

Hydraulic hoses (auxiliary piping)

Seat belt

Every 3 years

5-12

Maintenance

Safety-critical parts

The material of the safety-critical part listed above tends to change over time and cause wear

or deterioration. It is difficult to determine the degree of deterioration at the periodic inspection,

and thus they need to be replaced with new ones after a certain time to maintain their proper

performance even if they appear in good condition. Note that regardless of the replacement

schedule, replacement must be performed immediately if a symptom of wear is found. If a

hose clamp is deformed or cracked, replace it together with the hose immediately. When

replacing the safety-critical parts, ask your sales or service dealer.

In addition to the safety-critical parts, inspect the hydraulic hoses and retighten or replace as

necessary. When replacing the hydraulic hoses, replace the O-rings and seals at the same

time.

Check the fuel and hydraulic hoses according to the periodic schedule described below.

Refer to “Maintenance”.

Type of inspection

Inspection item

Leakage from the connecting parts of hydraulic or fuel hoses

Daily inspection

Damage to cab or canopy - replace*

Leakage from the connecting parts of hydraulic or fuel hoses

Monthly inspection

Damaged hydraulic or fuel hoses (cracks, wear and tear)

Leakage from the connecting parts of hydraulic or fuel hoses

Annual inspection

Deteriorated, twisted, damaged hydraulic or fuel hoses (cracks, wear

and tear) or hoses in contact with other parts of the machine

<Applicable machine models 216000002

or later>

*: Cab parts No. 03386-00101

*: Canopy parts No.(1) 03384-00135

*: Canopy parts No.(2) 03684-16300

<Applicable machine models 216100002

or later>

*: Canopy parts No.(1) 03384-00120

*: Canopy parts No.(2) 03384-00128

5-13

Maintenance

Maintenance list

Inspection and maintenance item

Page

Walk-around inspection

Inspecting by opening the engine hood and covers

5-16

Inspecting by walking around the machine

5-17

Inspecting while sitting in the operator’s seat

5-17

Daily inspection (every 10 hours)

Inspecting and replenishing the coolant

5-18

Inspecting and replenishing the engine oil

5-19

Inspecting the dust indicator

5-19

Inspecting the water separator

5-20

Inspecting the fuel level

5-20

Inspecting the hydraulic oil tank level and replenishing

5-21

Lubricating the working equipment

5-23

After the initial 50 hours (only for new machines)

Replacing the engine oil and the oil filter

5-24

Inspecting and adjusting the fan belt

5-25

Replacing the hydraulic oil return filter

5-26

Every 50 hours

Inspecting and adjusting the crawler tension

5-28

Lubricating the slew bearing

5-30

Lubricating the slew motor pinion

5-30

Draining the water from the fuel tank

5-31

Inspecting the battery fluid level and replenishing

5-32

Every 100 hours

Cleaning the water separator

5-34

Cleaning the fuel filter

5-34

After the initial 250 hours (only for new machines)

Replacing the travel motor gear oil*

5-35

Every 250 hours

Replacing the engine oil and the oil filter

5-36

Inspecting and adjusting the fan belt

5-36

Cleaning the air cleaner

5-36

Cleaning the radiator fins and oil cooler fins

5-38

Cleaning the air filters

5-39

*: If the percentage of the traveling time within the total operating time is high, replace the gear

oil earlier than the specified time.

5-14

Maintenance

Maintenance list

Inspection and maintenance item

Page

Every 500 hours

Replacing the hydraulic oil return filter

5-40

Replacing the water separator filter

5-40

Replacing the fuel filter

5-41

Every 1000 hours

Replacing the travel motor gear oil*

5-42

Cleaning the engine cooling system

5-42

Replacing the air cleaner element

5-44

Inspecting and adjusting the engine valve clearance

5-45

Retightening the engine cylinder head bolt

5-45

Every 1500 hours

Inspecting and cleaning the engine fuel injectors

5-46

Inspecting the crankcase breather system

5-46

Every 2000 hours

Lapping the engine valve seats

5-47

Every 4000 hours

Replacing the hydraulic oil and cleaning the suction strainer

5-48

When required

Replacing the bucket teeth

5-50

Replacing the bucket

5-52

Lubricating the levers

5-54

Inspecting the rubber crawlers

5-55

Replacing the rubber crawlers

5-56

*: If the percentage of the traveling time within the total operating time is high, replace the gear

oil earlier than the specified time.

5-15

Maintenance

Walk-around inspection

Perform the following inspections every day before starting the engine for the first time.

• Before operating, perform the walk-around inspections and make repairs immediately

where necessary.

• Be sure to secure the engine hood or cover before working the inside. Do not keep the

hood or cover open on a windy day or if the machine is parked on a slope.

Before starting the engine, look around the machine and clean any combustibles from the

surroundings of the engine. Also, inspect if oil or water is leaking and any nuts or bolts are

loosened.

Inspecting by opening the engine

3. Check for oil leakage from the hydraulic

hood and covers

tank, hydraulic devices, hoses or

connections.

1. Check for any twigs, leaves, oil or other

combustible materials around the engine

and battery.

2. Check for oil or engine coolant water

leakage around the engine.

5-16

Maintenance

Walk-around inspection

Inspecting by walking around the

Inspecting while sitting in the

machine

operator’s seat

4. Check lights for dirt, damage and burnt

14. Check the windshield for dirt or damage.

out bulbs.

15. Check the seat and seat belt for dirt or

5. Check attachments and hoses for

damage.

Check the operator’s seat for dirt, oil or

6. Check the bucket, bucket teeth and side

other combustible materials.

cutter for wear, damage and looseness.

16. Check the monitor, instruments and

7. Check the hook, slip stopper and hook

switches for dirt or damage.

mount of buckets with hooks for damage.

(Option)

8. Check the handrail and steps for damage

and loose bolts.

9. Check the crawlers, shoe slides, track

rollers, idlers and sprockets for damage,

wear and loose bolts.

10. Check for oil leakage from the travel

motor.

11. Check the canopy/cab and guard for

damage and the nuts and bolts for

looseness.

12. Check the rearview mirror and the interior

rearview mirror for dirt or damage, and

adjust them if necessary.

13. Check the labels for dirt and damage.

5-17

Maintenance

Daily inspection (every 10 hours)

Inspection

Daily inspection

(every 10 hours)

Perform the following inspections every day

before starting the engine for the first time.

• Before operating, perform the daily

inspections and make repairs

immediately where necessary.

• Be sure to secure the engine hood or

cover before working the inside. Do not

keep the hood or cover open on a windy

1. Open the engine hood.

day or if the machine is parked on a

2. Inspect the cooling water level in the

slope.

reserve tank (1).

The level should be between the upper

limit (H) and the lower limit (L).

If it is below the lower limit (L), replenish.

Inspecting and replenishing the

coolant

Replenishing

1. Remove the cap (2) of the reserve tank (1).

2. Add cooling water up to the upper limit (H)

of the reserve tank (1).

• Do not remove the radiator cap or the

If the reserve tank (1) is found empty at the

drain plug when the cooling water is

inspection, check for water leakage and

hot. Stop the engine and wait until the

then the water level in the radiator (3). Add

engine and the radiator cool before

water to the radiator (3) as required, and

slowly loosening the radiator cap and

then to the reserve tank (1).

the drain plug to remove them.

3. Install the cap (2).

• Always wear the protective goggle and

gloves when handling coolant

Note: Use only clean water (soft water) to

(antifreeze). If any coolant (antifreeze)

replenish the cooling water loss due to

comes in contact with eyes or skin,

evaporation. Use coolant (antifreeze) and

wash it off with clean water. Otherwise,

clean water (soft water) of the specified

it could result in injures.

mixing ratio to replenish the cooling water

loss due to leaking.

5-18

Maintenance

Daily inspection (every 10 hours)

Inspecting and replenishing the

Inspecting the dust indicator

engine oil

Stop the engine and allow the machine to

cool down before performing

maintenance.

The dust indicator is the equipment to be

used to find out if there is clogging in the air

Inspection

cleaner.

1. Open the engine hood.

1. Open the maintenance cover A.

2. Take out the dipstick (1) and wipe the oil

2. Check that if the red piston (2) is shown in

off with a rag.

the dust indicator (1).

3. Fully reinsert the dipstick (1), and then pull

3. If the red piston (2) is visible, immediately

it back out.

clean or replace the element.

4. Check the oil on the dipstick (1).

Refer to “Cleaning the air cleaner” on page

The level should be between the upper

5-36.

limit (H) and the lower limit (L).

4. After cleaning/replacement, push the

If it is below the lower limit (L), replenish.

button (3) on the dust indicator to reset

the red piston (2).

Replenishing

1. Remove the oil filler cap (2).

2. Add oil up to between the upper limit (H)

and the lower limit (L) of the dipstick (1).

Problems could arise if the oil level is either

too low or too high.

3. Tighten the oil filler cap (2).

4. Start the engine, run it at low idle for about

5 minutes, then stop it.

5. After about 10 minutes, inspect the oil

level.

5-19

Maintenance

Daily inspection (every 10 hours)

Inspecting the water separator

Inspecting the fuel level

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Stop the engine in a well-ventilated

• Never remove the fuel cap or add fuel

place and allow it to cool down before

when the engine is running or still hot.

performing maintenance.

Do not spill fuel on the hot surface of

• Clean up spilled fuel immediately.

the machine.

• Fill the fuel tank in a well ventilated

place.

• Clean up spilled fuel immediately.

• Do not fill the fuel tank to capacity.

Allow room for oil expansion.

• Securely tighten the fuel filler cap.

• Use the correct grade of fuel for the

operating season.

1. Open the engine hood.

2. Inspect the water separator (1).

If the red indicator ring (6) is sunk to the

bottom of case (4), no water is mixed in.

If the red indicator ring (6) is floating, there

is water up to the ring. Drain the water

and clean.

Refer to “Cleaning the water separator” on

page 5-34.

1. Check the fuel level using the fuel gauge

Refer to “Bleeding air from the fuel

(1).

system” on page 6-8.

F: Tank is full.

E: Tank is empty.

2. If the fuel level is low, open the fuel lid.

3. Add fuel from the fuel filler port (2) while

watching the sight gauge (3).

Use this gauge (3) to check the full state

when adding fuel. For checking the

remaining amount, use the gauge in the

instrument cluster.

Refer to “Fuel filler port” on page 2-8.

5-20

Maintenance

Daily inspection (every 10 hours)

Inspecting the hydraulic oil tank

Replenishing

level and replenishing

Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

• Press the air breather button to relieve

the internal pressure from the tank.

Inspection

IMPORTANT: Do not fill up to the level

The oil level changes with the oil

higher than the upper limit (H). It will

temperature. Inspect the oil by maintaining

damage the hydraulic circuits or result in

the machine at posture shown in the figure at

oil spurting. If accidentally done, stop the

the next.

engine and wait the hydraulic oil to cool,

• Machine posture for inspecting the

and then let the excessive oil to drain

hydraulic oil level

from the drain plug.

IMPORTANT: Do not forget to apply

pressure to the hydraulic tank to avoid

damage to the pump caused by air

sucking.

1. Open the engine hood.

2. Slowly loosen the air bleeding plug (2) to

relieve the internal pressure, and then

remove it.

3. Add the hydraulic oil up to the middle of

the sight gauge (1).

4. Pressurize the hydraulic oil tank as follows.

1. Start the engine and run it at low speed.

2. Fully retract the cylinders (arm and

bucket), and lower the bucket to the

ground.

3. Lower the dozer blade, and then stop the

engine.

4. Inspect the oil level using the sight gauge

(1).

· When the oil temperature is about 20°C

(68°F):

The level should be between the upper

limit (H) and the lower limit (L).

If it is below the lower limit (L), replenish.

· When the oil temperature is about 50 to

80°C (122 to 176°F):

The level should be slightly below the

upper limit (H).

5-21

Maintenance

Daily inspection (every 10 hours)

Pressurizing the hydraulic tank

1. Start the engine and run it at low speed.

2. With the vent plug (2) removed, set the

safety lock levers to the released position.

· Hydraulic tank pressurization posture

3. Fully extend the bucket, arm, boom, swing

and span cylinders.

4. Stop the engine and raise the left safety

lock lever to engage the lock.

5. Tighten the vent plug (2), and then

pressurize by retracting the cylinders.

5-22

Maintenance

After the initial 50 hours (only for new machines)

2. Place a pan for catching the waste oil

After the initial 50

under the drain plug (3).

3. Remove the cap (A), install connector (B)

hours

and drain the oil. (The oil comes out when

the screw is tightened.)

(only for new machines)

4. Remove the connector (B) and install the

Replacing the engine oil and the

cap (A).

oil filter

IMPORTANT: Check the waste oil for

metal powder. If it contains large amounts

of metal powder, consult your sales or

Stop the engine and allow the machine to

service dealer.

cool down before performing

maintenance.

5. Turn the filter (4) counterclockwise with the

• The engine, muffler, radiator, hydraulic

filter wrench and remove it.

lines, sliding parts and many other parts

6. Clean the surface of installation of the filter

of the machine are hot immediately after

stand.

the engine is stopped. Touching these

7. Apply a thin layer of oil on the packing of

parts will cause burns.

the new filter.

• The engine oil is also hot.

8. Install the new filter by hand.

Be careful not to touch the hydraulic oil

9. Tighten one more turn (with the filter

when loosening the cap or plug.

wrench) after the filter packing comes in

Working on the machine under these

contact with the surface of installation.

conditions could result in burns or

(Torque when tightening with filter wrench:

injuries.

19.6 to 23.5 N·m or14 to 17 ft-lb)

10. Add oil up to between the upper limit (H)

and the lower limit (L) of the dipstick (1).

Problems could arise if the oil level is

either too low or too high.

11. Tighten the oil filler cap (2).

12. Start the engine, run it at low idle for

about 5 minutes, then stop it.

13. After about 10 minutes, inspect the oil

level.

1. Open the engine hood and remove the oil

filler cap (2).

5-24

Maintenance

After the initial 50 hours (only for new machines)

Inspecting and adjusting the fan

3. Press at the center of the fan pulley (1)

belt

and alternator pulley (2) to check the

tension (approx. 98 N or 22 lbf).

The slack (A) should be 7 to 10 mm (0.28

to 0.4 in).

Stop the engine and allow the machine to

4. Inspect the fan belt (3) and replace if it is

cool down before performing

as follows.

maintenance.

· There are cuts or cracks.

• The engine, muffler, radiator, hydraulic

· The belt is worn and touches the bottom

lines, sliding parts and many other parts

of the V groove in the pulley.

of the machine are hot immediately after

· The belt stretched too loose to be

the engine is stopped. Touching these

adjusted.

parts will cause burns.

Adjustment

IMPORTANT: The loose belts could result

in bad battery charge, overheat of engine

or early wear of belt. Too tight belts could

damage the water pump or bearing and

belt used to drive the alternator.

IMPORTANT: Do not let any oil or grease

get on the belt.

Inspection

1. Loosen the bolt (5) and locking nut (4).

2. Turn the adjustment bolt (6) to move the

alternator (7) and to adjust the tension of

the fan belt (1).

· Tighten: Clockwise

· Loosen: Counterclockwise

3. Tighten the bolt (5) and locking nut (4).

Note: When replacing with a new belt, run

1. Move the sheet all the way forward.

the engine at low idle speed for about 3 to 5

2. Take out three bolts and remove the cover

minutes to break in the new belt, before

(1).

adjusting the tension.

5-25

Maintenance

After the initial 50 hours (only for new machines)

Replacing the hydraulic oil

return filter

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine and the hydraulic system

and many other parts of the machine

are hot immediately after the engine is

stopped. Touching these parts will

1. Open the engine hood.

cause burns.

2. Slowly loosen the air bleeding plug (1) to

· The hydraulic oil is also hot and under

relieve the internal pressure, and then

high pressure.

remove the plug.

Be careful not to touch the hydraulic

oil when loosening the cap or plug.

Working on the machine under these

conditions could result in burns or

injuries due to the hot oil spurting out.

• Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

· Gradually loosen the vent plug to

relieve tank pressure.

· When removing plugs or screws, or

when disconnecting hoses, stand to

the side and loosen them slowly to

gradually release the internal pressure

before removing.

5-26

Maintenance

Every 50 hours

Inspection

Every 50 hours

Inspecting and adjusting the

crawler tension

• If you must work beneath the raised

machine or working equipment, always

use wood blocks, jack-stands or other

rigid and stable supports. Never get

under the machine or working

AD6G013

equipment if they are not sufficiently

supported. This procedure is especially

1. For rubber crawlers, move the machine so

important when working on hydraulic

that the “M” or “∞” mark at the joint is at

cylinders.

the top center of the crawler frame.

• Be careful with the high-pressure grease

In the track adjuster, the grease has

been injected under high pressure. If the

tension is adjusted without following the

prescribed procedure, the grease

discharge valve may fly off, resulting in

injury.

· Never loosen the grease fitting.

· Loosen the grease discharge valve

slowly. Do not turn it more than one

turns.

· Do not put your face, arms, legs or

body in front of the grease discharge

2. Use the working equipment to lift the

valve.

machine body. Operate the levers slowly.

· If grease does not come out when the

grease discharge valve is loosened,

the valve is faulty. Ask a Takeuchi

service agent for repair.

5-28

Maintenance

Every 50 hours

Adjustment

Increasing the tension

AD6G014

3. Inspect the gap (A or B) between the

bottom surface of the frame at the center

of the crawler frame and the top surface of

the crawler.

The gap (A or B) must be within the

1. Remove the cover (1).

following range:

2. Inject grease through the grease fitting (3)

of the grease discharge valve (2) with a

(A) Rubber crawler

grease gun.

59 to 64 mm (2.3 to 2.5 in.)

3. Inspect the crawler tension.

(B) Steel crawler

84 to 89 mm (3.3 to 3.5 in.)

Decreasing the tension

1. Remove the cover (1).

2. Slowly loosen (one turn) the grease

discharge valve (2) with a spanner to

discharge grease. If grease does not

come out well, move the machine back-

and-forth.

3. Tighten the grease discharge valve (2).

· Tightening torque: 177 N·m (130 ft-lb.)

5-29

Maintenance

Every 50 hours

Lubricating the slew bearing

Lubricating the slew motor pinion

Do not slew while lubricating. Doing so is

dangerous, as you may get caught in the

machine.

1. Use the grease gun to lubricate the grease

fitting (2).

2. Wipe off the excess grease.

1. Stop the engine with the machine in the

posture shown on the figure above.

2. Use the grease gun to grease the grease

fitting (1).

3. Start the engine, lift the bucket and slew

clockwise 90°.

4. Lower the bucket to the ground, and then

stop the engine.

5. Repeat the steps 2 to 4 above three

times.

6. Wipe off the grease expelled from the slew

bearing and grease fitting.

5-30

Maintenance

Every 50 hours

Draining the water from the fuel

Bleeding air from the fuel system

tank

Refer to “Bleeding air from the fuel system”

on page 6-8.

Note: Air in the fuel system causes the

• Do not smoke or permit open flames

engine to fail to start or to have problems.

while handling fuel or working on the

Bleed air when the fuel tank is emptied,

fuel system.

using the same procedure above.

• Never remove the fuel cap or add fuel

when the engine is running or still hot.

Do not spill fuel on the hot surface of

the machine.

• Fill the fuel tank in a well ventilated

place.

• Do not fill the fuel tank to capacity.

Allow room for oil expansion.

• Clean up spilled fuel immediately.

• Securely tighten the fuel filler cap.

• Use the correct grade of fuel for the

operating season.

Do the draining operation before starting the

machine.

1. Slew the upperstructure to the position for

easy draining.

2. Remove the fuel filler cap (2).

3. Place a pan under the drain plug (3).

4. Loosen the drain plug (3) to drain water

and sediment buildup in the bottom of the

tank.

5. Tighten the drain plug (3).

6. Add fuel while watching the sight gauge

(1).

7. Tighten the fuel filler cap (2) and lock it.

8. Bleed air.

5-31

Maintenance

Every 50 hours

Inspecting the battery fluid level

Inspection

and replenishing

1. Open the maintenance cover.

• Do not use the battery when the fluid

level is below the lower level limit. Doing

so will hasten the deterioration of the

internal portions of the battery and

shorten the battery life. It also can

cause rupturing (explosion).

• Batteries generate flammable hydrogen

gas which may explode. Keep away

from flame, sparks, fire or lighted

cigarettes.

• Use a dampened cloth to clean above

2. Inspect the fluid level.

the fluid level line and check the fluid

The fluid level must be between the upper

level. Do not clean with a dry cloth;

level line (H) and lower level line (L). If not,

otherwise it can cause static electricity

add distilled water up to the line (H).

to build up, resulting in ignition or

3. Check the terminals for looseness and

explosion.

dirt.

Replenishing

When adding distilled water, do so before

• Wear protective goggle and clothing

starting operations in order to prevent

when working with batteries.

freezing.

• Do not add the distilled water above the

1. Remove the caps (1), and add distilled

upper level limit. Doing so could cause

water until the upper level (H).

the fluid to leak. This fluid can cause

2. Clean the exhaust hole on the cap, then

skin damage if contacted, or can cause

tighten the caps (1) securely.

the machine components to corrode.

• Batteries contain sulfuric acid which will

damage eyes or skin if contacted.

· If eye contact occurs, flush

immediately with clean water and get

prompt medical attention.

· If accidentally swallowed, drink large

quantities of water or milk and call a

physician immediately.

· If acid contacts skin or clothing, wash

off immediately with a lot of water.

5-32

Takeuchi Mini Excavator TB216 (No.216000002~, No.216100002~). Operator's Manual - page 4